April 18./19.2016 | Andreas Grunicke
thyssenkrupp Marine Systems – Operating Unit Submarines
Technology Development - New Technologies
FICCI Conference, New Delhi
Content
1. Introduction 2. Li Ion Batteries
3. Fuel Cell Methanol Reformer System 4. IDAS
5. Hydrodynamics, propeller development 6. Acoustic Coating
7. UUV integration concepts
8. Summary
thyssenkrupp – Organizational overview
thyssenkrupp Business Areas
Industrial Solutions Components
Technology Materials
Services Steel
Americas Elevator
Technology
Sales (€ mill) 6,753 EBIT
2)(€ mill) 313 Employees 29,627
Sales (€ mill) 7,208 EBIT
2)(€ mill) 794 Employees 51,335
Sales (€ mill) 6,256 EBIT
2)(€ mill) 424 Employees 19,388
Sales (€ mill) 14,254 EBIT
2)(€ mill) 206 Employees 20,.226
Steel Europe
Sales (€ mill) 8,697 EBIT
2)(€ mill) 492 Employees 27,601 Sales (€ mill) 1,773
EBIT
2)(€ mill) (138)
Employees 3,725
Key indicators – fiscal year 2014/2015
1)thyssenkrupp Marine Systems – Operating Units
Business Unit thyssenkrupp Marine Systems
Atlas Elektronik
Submarines Surface Vessels Services
Kiel Hamburg/Emden Kiel/Hamburg/Emden
Operating Units
Generic Tasks of Research and Development
Enhancement of Customer Value Cost Reduction
Risk Reduction
Mid- and Long-Term Enhancement of Competitiveness
Technology Leadership
Cost Leadership
Scope of Research and Development Activities
R&D - Activi- ties
Products
Components and Systems
Processes and Tools
5000 10000
15000 20000
0.005 0.01
0.015 0.02 -15
-10 -5
0
5000 10000
15000
Research& Development Expenditure
25
43
33 22 21
16
1, 8
3
3, 2 3
6
6
24 3 2
FY 10/11 FY 11/12 FY 12/13 FY 14/15
50
2
18
3
40
FY 13/14 28
FY 15/16 2
OU Services
OU Surface Vessels OU Submarines
Mio. EUR
More than 160 R+D projects running at present time 24
3
Long Lasting Developments 1
1 From start of development to delivery of first submarine with this technology
Weapon Section
Torpedo Counter Measures
ISUS 90 Family PERMASYN® Motor Fuel Cell System IDAS
Lithium Battery System Class 212
Class 214
1988 - 1994 1999 - 2005
1990 - 2005 1985 - 2005 1980 - 2005 1996 -
2003 -
1987 - 2005
1996 - 2007
Lithium Ion Batteries - Introduction and Motivation
▪ Extend time submerged
▪ Increase speed spectrum while submerged
– Complement to the AIP-System designed to fulfill low power requirements
▪ Decrease indiscretion rate
– Improved charging and discharging characteristics
▪ Increase availability
– Decrease maintenance requirements
▪ Decouple submarine performance from battery characteristics (as much as possible)
– High speed independent from State of Charge (SoC)
▪ Extend life time.
To Improve Operational Value of the Submarine
Technical Concept
How about Performance?
0 20 40 60 80 100 120 140
100 80
60 40
20
0 Speed
percent Range
percent
Lead Acid 80%
LIB 93%
▪ Under low load conditions: 20% more capacity
▪ Under high load conditions: 200% more capacity
▪ Performance independent of SoC
▪ Available capacity is not degrading during
mission and can be charged using charging stage
1 only (leading to reduced indiscretion rate)
Comparison of Charging Times
• Boundary Conditions
− Both batteries are discharged with the same charging power
− Both batteries are discharged the same time (same discharged energy)
− Both batteries are charged with the same max. charging power
− Lead Acid Battery: Charging Step 1 with max. power, charging step 2 with max Voltage and reduced current (= reduced charging power)
− Li Ion Battery: Only charged in charging step 1
− The charging time of the Li Ion battery is approx. 28% less
than the charging time of the lead acid battery. This means
improved Indiscretion Rate
Optimization of Transit SOA
• Lead Acid Battery
− Case (0): Optimized transit SOA for Indiscretion Rate
• Li-Ion Battery
− Case (1): Same speed combination as in case (0)
− Case (2): Same SOA as in case (0)
− Case (3): Same IR as in case (0)
Major Integration Aspects
System Safety is Critical!
A damage and risk assessment lead to high safety integrity level (>= SIL4) requirement for the control electronics when NCA/NMC/NCO is used.
▪ There are intrinsically safe chemistries
– LFP – Lithium-Iron-Phosphate.
▪ Overcharge
▪ Overload
▪ Overheat
▪ Mechanical Damage
▪ Internal Short
Risk
▪ Thermal Runaway and the chain reaction within the battery compartment
▪ High Energy Chemistries bear the risk of open fire in the battery compartment
– NCA – Nickel-Cobalt-Aluminum
– NMC – Nickel-Manganese-Cobalt
– NCO – Nickel-Cobalt-Oxide
Trigger
A manufacturer’s quality assurance issue with a remaining risk To be handled by mechanical integration
To be handled by control electronics
Battery Development at thyssenkrupp Marine Systems
Decision
▪ Selection of well established cell manufacturer with system development competency
▪ Standard cell as core element
▪ Selection of LFP (blend) as the cell chemistry
▪ Focus on system integration as thyssenkrupp Marine Systems
expertise.
Lithium-Ion Battery Integration into the Submarine
Cl. 214
Number of modules transversal 12
Number of modules longitudinal 2 x 16
Module voltage [V] 89 - 125
Energy per module [kWh] 38
Total number of modules 384
Number of modules per string 6
String voltage range [V] 535 - 752
Engine voltage range [V] 520 - 830
Number of strings 64
Total number of cells 101376
Energy [MWh] 14,5
Methanol Reformer – Why start the Development
Fuel cell with methanol reformer Fuel cell with metal hydrides Weight/Volume of energy
storage and conversion
AIP energy to store
Power Supply
surface- / snorkel operation submerged operation
fuel oil
air
diesel generator battery
propulsion system
&
hotel load FC
reformer
O2 H2
Source: Siemens, Gaia, MTU, Piller
Hydrogen Generation by Methanol Steam Reforming
▪ Simple alcohol CH 3 OH
▪ Lowest reforming temperatures of 250 ° - 300 ° C
▪ Cheap and easily available worldwide (like LOX)
▪ Methanol steam reforming is a proven technology in the process industry
CH 3 OH + H 2 O 3H 2 + CO 2
Best choice for hydrogen generation on submarines
Fuel Cell Methanol Reformer System
The Fuel Cell Methanol Reformer System (FCMRS) combines the advantage of the existing, proven Fuel Cell System with the advantage to utilize a liquid fuel with high energy density. A first demonstrator has been operated since the year 2000
The reformer prototype system has been set into operation in the test field at thyssenkrupp Marine Systems premises in Kiel in summer 2015.
The system has already successfully produced ultra-pure hydrogen. Furthermore the Fuel Cell Modules have been operated on hydrogen produced by the reformer system.
Fuel Cell Modules
Methanol Reformer
IDAS at a Glance
• IDAS – Ch anging the paradigms of anti submarine warfare!
− Active self defence against airborne ASW for submerged submarines
− High precision through Human in the Loop Concept
− Coastal and small surface targets attack capability
Operational Concept
The IDAS Target Spectrum
Defensive Role Offensive Role
Weapon of choice for targets which are too fast or not accessible for a heavy weight torpedo, or for which a torpedo is over dimensioned
Technical Concept
• IDAS Submarine Integration
Operator controlled during the whole mission Very easy integration, handling with existing equipment for standard
heavy weight torpedoes
Technical Concept
• IDAS Launching Container System
− Four (4) missiles per launching container
− All launching subsystems in container (autonomy)
− Weight/ dimensions comparable to heavy weight torpedo, easy retrofit to all standard torpedo tubes
• Main Technical Data
− Launching Mass: 138 kg
− Length: 2800 mm
− Diameter / Caliber: 180 / 240 mm
The IDAS Missile
− Mass of Warhead: 15-20 kg
− Range: approx. 20 km
− Cruising Speed: approx. 230 m/s
IIR Seeker &
Guidance Section
Warhead Section
Rocket Motor & Wing Section
Sustainer Booster
Control
Bobbin
System
Section
Unmanned Underwater Vehicles on Submarine
• What is the original purpose of unmanned underwater vehicles?
• Normally
− AUVs bring sensors from the surface
− down in the ocean
− close to the targets
− away from disturbing noise and vibrations
• Submarines
− AUVs bring sensors from down into the ocean
− away from the submarine
− to areas of very shallow waters
− to the surface
− to areas with a high risk for Manned Underwater Vehicles.
Reference: Kongsberg Maritime AS
Tasks of UUVs Deployed by Submarines
− Rapid environmental assessment (REA)
− sonar images and conditions
− bathymetric data
− water current information
− mine reconnaissance
− pictures of underwater objects
− Preparation and assistance of landing activities
− actual situation assessment
− guidance of the combat diver teams
− visual escorting of landing forces on/offshore
− communication relay
Meanwhile the submarine could stay covert
Observing areas which were inaccessible for conventional submarines In parallel while the submarine fulfils other tasks.
online data link to the submarine
Concept Idea – UUV Launch & Recovery System for Submarines
• Capable for retrofitting on existing HDW Class Submarines
− less conversion effort
− easy to handle and simple interfaces
− also for new submarine projects
• Minimized negative influence on the present submarine performance
− no additional signatures
− not visible if the submarine is surfaced
− no disturbing flow noise around stowage devices
− no further appendages
− no increased drag or manoeuvring limitations for the submarine
− no/minimal increased weight
Only two options for integration UUVs on submarines.
Weapon tubes Upper deck
inside casing
Launch & Recovery System for Weapon Tubes
− e.g. AUV DAVID made by Diehl BGT Defences
Launch & Recovery System for Weapon Tubes
− e.g. AUV DAVID made by Diehl BGT Defences
Launch & Recovery System for Weapon Tubes
− Horizontal movement in the weapon tube
Launch & Recovery System for Weapon Tubes
− Launching of the AUV
Launch & Recovery System for Weapon Tubes
− Recovery of the AUV
Launch & Recovery System for Weapon Tubes
− Retraction into the weapon tube.
• Main dimension fit for weapon tube concept
− Modification for use inside weapon tubes
− Ruder dimensions
− Sail and com antenna
− Recovery hook
SeaCat MKI (ATLAS ELEKTRONIK)
Reference: ATLAS ELEKTRONIK
• Experience with launch & recovery procedure
• Next practical trials focusing
− autonomous location
− reacting on movements of submarine
− data communication
• Interim launch & recovery device for SeaCat MKI
Continuation with SeaCat MKI
• Autonomous locating…
• and docking of SeaCat MKI into interim launch & re- covery device
• …and launching
Latest Harbour Trials Summer 2015
Reference: thyssenKrupp Marine Systems & ATLAS ELEKTRONIK
Conclusion
• Reached Aims at launch & recovery
− Mechanical function demonstrated
− Drive in & out by AUV impellent
− Autonomous locating and manoeuvring
to recovery device
Results and Next Steps
− Functionality of the weapon tube L&R device was demonstrated at harbour trails
− Modification on our launch &
recovery system for trials inside a weapon tube
− Changeover to the SeaCat System from ATLAS ELEKTRONIK .
Reference: ATLAS ELEKTRONIK
